Resealable container including release elements

ABSTRACT

A container for consumer goods that comprises a housing (12) comprising a box (14) and a lid (20) hingedly attached to the box. The box comprises a box front wall (16) and an interior box volume. The lid comprises a lid front wall (24). The container also comprises a sealed inner package (30) disposed at least partially within the interior box volume and defining an interior sealed volume for housing consumer goods. The container also comprises a resealable flap (44) configured to open and close the sealed inner package when the lid of the housing is opened and closed. The resealable flap (44) being positioned to cover an access opening (54) in the sealed inner package that extends at least partially across the top wall of the inner package. The container also comprises at least one release element (72) positioned within the interior sealed volume of the sealed inner package even after the sealed inner package has been opened and closed.

The present invention relates to a container for consumer goods with aresealable inner package that contains one or more release elements toprovide sensory-enhancing components such as flavourants, humidificationor both to the consumer goods. The container finds particularapplication as a container for elongate smoking articles such ascigarettes.

Smoking articles such as cigarettes and cigars are commonly sealedduring manufacturing by shrink wrapping an outer wrapper around thecardboard package. Resealable packages have offered some measure ofcontrol however there remains a desire to be able to further control thehumidification, flavour or both of the articles.

International patent applications WO 2009/092823 and WO 2005/070241 bothrelate to packs for tobacco industry products that include a capsulecontaining a substance such as a flavouring substance. Upon opening thepack, the flavouring substance is manually released from the capsule andabsorbed by the products disposed in their pack to refresh theirflavour. However, since by the time the packs are opened the shrinkwrapped outer wrapper has been at least partially been removed, theflavour or moisture added with the capsule is quickly lost.

Accordingly, an object of the present invention is to provide acontainer for consumer goods that provides a consumer with thepossibility to activate additional flavour or moisture but allows theretention of the additionally released material over an extended amountof time.

The current invention is directed to a container for consumer goods,comprising a housing comprising a box and a lid hingedly attached to thebox, wherein the box comprises a box front wall and an interior boxvolume and wherein the lid comprises a lid front wall and a sealed innerpackage disposed at least partially within the interior box volume anddefining an interior sealed volume for housing consumer goods. Aresealable flap is configured to open and close the sealed inner packagewhen the lid of the housing is opened and closed. The resealable flap ispositioned to cover an access opening in the sealed inner package, wherethe access opening extends at least partially across the top wall of theinner package. At least one release element is positioned within theinterior sealed volume of the sealed inner package even after the sealedinner package has been opened and closed.

In one aspect of the present invention, the release element or releaseelements can be enclosed within the resealable inner package andtherefore do not interfere with the opening or closing of the innerpackage. In yet other aspects of the present invention, where there ismore than one release element, the release or release elements can beindependently modulated to release the flavourant or flavourants, wateror both contained in each element.

In further aspects of the present invention, the inner liner can includeindicia that inform the location, identities, or both of the releaseelement or release elements.

In additional aspects of the invention, the release element or releaseelements can be disposed between an inner stiffener and the inner linerof the resealable inner package to ensure that the articles within theresealable inner package are not damaged by the application of pressureto break the release element or release elements.

Various aspects of the present invention may provide one or moreadvantages relative to currently-available or previously-describedcontainers. For example, the one or more release element or releaseelements may afford the ability to include flavouring, humidification,or both to consumer articles in a resealable package. The flavouring,humidification, or both can be maintained even after the container isopened for the first (and subsequent) times. Furthermore, the ability toinclude more than one release element or release elements that can beindependently actuated may afford the ability to tailor the flavouringsprovided to the consumer goods. Additionally, indicia on the inner linercan indicate location, identities, or both of the one or more releaseelement or release elements.

The present invention is applicable to any suitable container forconsumer goods such as for example elongate smoking articles. It isknown to package consumer goods such as, for example, elongate smokingarticles in containers formed from folded laminar blanks. For example,elongate smoking articles, such as cigarettes and cigars, are commonlysold in hinge lid packs having a box for housing the smoking articlesand a lid connected to the box about a hinge line extending across theback wall of the container.

The container may take any suitable form for housing consumer goods. Forexample, as already mentioned, the container may comprise a housing thatcan be described as a hinge-lid container of the Flip-Top® type with ahinged lids connected to a box housing the consumer goods. In one ormore embodiments, the container may be a slide and shell containerhaving an inner slide for housing the consumer goods mounted within anouter shell. Where the container is a slide and shell container, theouter shell or the inner slide may include one or more hinge lids. Thecontainer may be formed from any suitable materials including, but notlimited to, cardboard, paperboard, plastic, metal, other materials, orcombinations thereof. The cardboard may have a weight of between about100 grams per square meter and about 350 grams per square meter.

Containers described herein will generally have the same or a similarshape as the housing. As such, housings according to the invention maybe in the shape of a rectangular parallelepiped, with right-angledlongitudinal and right-angled transverse edges. Alternatively, thehousing may comprise one or more rounded longitudinal edges, roundedtransverse edges, bevelled longitudinal edges, or bevelled transverseedges, other types of edges, or combinations thereof. For example, thehousing according to the invention may comprise, without limitation, oneor more of the following features:

-   -   one or two longitudinal rounded or bevelled edges on at least        one of the front wall and the back wall;    -   one or two transverse rounded or bevelled edges on at least one        of the front wall and the back wall;    -   one longitudinal rounded edge and one longitudinal bevelled edge        on the front wall, or one transverse rounded edge and one        transverse bevelled edge on the back wall;    -   one longitudinal rounded edge and one longitudinal bevelled edge        on the front wall, and one transverse rounded edge and one        transverse bevelled edge on the back wall;    -   one or two transverse rounded or bevelled edges on the front        wall and one or two longitudinal rounded or bevelled edges on        the front wall; and    -   two longitudinal rounded or bevelled edges on a first side wall        or two transverse rounded or bevelled edges on the second side        wall.

Where the housing comprises one or more rounded edges, preferably theblanks forming the housing comprise three, four, five, six, or sevenscoring lines or creasing lines to form each rounded edge in theassembled container. The scoring lines or creasing lines may be eitheron the inside of the housing or on the outside of the housing.Preferably, the scoring lines or creasing lines are spaced from eachother by between about 0.3 millimetres (mm) and 4 mm.

Preferably, the spacing of the creasing lines or scoring lines is afunction of the thickness of the laminar blank. Preferably, the spacingbetween the creasing lines or scoring lines is between about 0.5 andabout 4 times larger than the thickness of the laminar blank.

Where the housing comprises one or more bevelled edges, preferably thebevelled edge has a width of between about 1 mm and about 10 mm,preferably between about 2 mm and about 6 mm. In one or moreembodiments, the housing may comprise a double bevel formed by threeparallel creasing or scoring lines that are spaced such that twodistinct bevels are formed on the edge of the container. Where thehousing comprises a bevelled edge, the bevel may be formed by twoparallel creasing lines or scoring lines in the laminar blank from whichthe container is formed. The creasing lines or scoring lines may bearranged symmetrically to the edge between a first wall and a secondwall. Alternatively, the creasing lines or scoring lines may be arrangedasymmetrically to the edge between the first wall and the second wall,such that the bevel reaches further into the first wall of the containerthan into the second wall of the housing.

Alternatively, the housing may have a non-rectangular transverse crosssection, for example, polygonal such as triangular or hexagonal, oroval, semi-oval, circular or semi-circular.

Containers according to the invention find particular application aspacks for elongate smoking articles such as, for example, cigarettes,cigars or cigarillos. In other embodiments, the consumer goods may beaerosol-generating articles such as articles that heat but not burntobacco. It will be appreciated that through appropriate choices of thedimensions thereof, containers according to the invention may bedesigned for different numbers of conventional size, king size,super-king size, slim or super-slim cigarettes. Through an appropriatechoice of the dimensions thereof, containers or housings according tothe invention may be designed to hold different total numbers of smokingarticles, or different arrangements of smoking articles. For example,through an appropriate choice of the dimensions thereof, containers orhousings according to the invention may be designed to hold a total ofbetween ten and thirty smoking articles.

As well as housing a bundle of smoking articles, the container mayfurther comprise other consumer goods, for example, matches, lighters,extinguishing means, breath-fresheners, or electronics. The otherconsumer goods may be attached to the outside of the container,contained within the container along with the smoking articles, in aseparate compartment of the container, or any combination thereof.

Disclosed containers comprise a housing. The housing has an innersurface and an outer surface. The housing also has a rear wall, a frontwall and two side walls. The housing comprises a lid and a box.

The lid of the housing is hingedly attached to the box and is adapted tobe manipulated between an open position and a closed position. In theopen position, the consumer can access the consumer goods disposedwithin the housing. The lid is hingedly attached to the box along ahinge line that extends across the rear wall or the upper edge of therear wall of the housing. A hinge line may be, for example, a fold lineor a score line in the panel forming the back wall of the housing. Thelid and box are further defined by an opening line. The opening linerefers to the delineation between the lid and the box which begins atone end of the hinge line traverses the right side of the housing, thefront of the housing then the left side of the housing, or vice versa,and ends at the other end of the hinge line.

Preferably, the lid comprises a lid front wall, a lid left side wall, alid right side wall, a lid back wall, and a lid top wall. The lid has aninner surface and an outer surface. The front wall of the lid also has alower edge.

Preferably, the box comprises a box front wall, a box left side wall, abox right side wall, a box back wall, and a box bottom wall. The box hasan inner surface and an outer surface. The front wall of the box has anupper edge, which when the container is closed at least partially meetsthe lower edge of the lid. The box defines an interior box volume.

The container also comprises an inner package. Preferably, the innerpackage is initially sealed and may be resealed after opening; as such,the inner package can be referred to as either a sealed inner package ora resealable inner package. The sealed inner package is disposed withinthe housing of the container. The sealed inner package is moreparticularly disposed at least partially within the interior box volume.The sealed inner package defines a sealed interior volume within. Thesealed inner package can be configured to house or hold consumer goods.Illustrative consumer goods can include smoking articles such aselongate smoking articles. Specific illustrative elongate smokingarticles can include for example cigarettes, cigars, cigarillos consumergoods such as aerosol-generating articles that heat but not burntobacco, or combinations thereof.

Preferably, the sealed inner package is made of any suitable materials,for example, polymeric materials, metal foils, other materials, orcombinations thereof. The sealed inner package preferably comprisespolymeric materials such as polyethylene films, polyolefin films, polylactic acid (PLA) films, or some combination thereof. Preferably, thesealed inner package can comprise a first layer and a second layer thatare attached, at least at their peripheries to form a package with aninterior sealed volume. The interior sealed volume, when housed in thehousing is substantially the same before opening and after resealing.

Preferably, the sealed inner package comprises a top wall, a bottomwall, a front wall, a back wall, a right side wall and a left side wallwhen housed in the housing. The sealed inner package comprises an accessopening that affords access to the consumer goods housed inside when thesealed inner package is opened. A resealable flap associated with thesealed inner package covers the access opening when the container andthe resealable flap are in a closed position. The access opening is atleast partially uncovered when the container and the resealable flap arein the open position. The access opening can be cut duringmanufacturing, for example. Preferably, the resealable flap forms anS-shape, a curve with at least two turning points when the resealableflap is open.

The access opening can extend at least partially across the top wall ofthe sealed inner package. Preferably, the access opening can at leastpartially extend across the front wall of the inner package, the backwall of the inner package, or some combination thereof. In someembodiments, the access opening can extend at least into the area of thesealed inner package that is above the box front wall upper edge.

The container also comprises a resealable flap. The resealable flap canbe integrally formed from the sealed inner package, for example from amultilayer sealed inner package or can be a separate label configured towork with the sealed inner package to seal and reseal the sealed innerpackage. In some embodiments, the first layer of a multilayer innerpackage forms the resealable flap. Such an integrally formed resalableflap can be attached to the inner surface of the lid, via adhesive, orotherwise. In some embodiments, the resalable flap can be a separatelabel attached to the inner surface of the lid with one or more adhesiveportions that is configured to seal and reseal the sealed inner package.

In some embodiments, the sealed inner package, or preferably a portionof the sealed inner package that is part of the access opening comprisesor can be coupled to a resealable label. The resealable label can beconfigured to attach the portion of the sealed inner package to theinner surface of the lid as well as reseal the sealed inner package. Insuch an embodiment, when opening the lid and the sealed inner package, aportion of the second layer attached to the flap, the sealing region,are separated from each other along first and second cut linesrespectively to reveal the access opening. The resealable label can beattached to the lid using any suitable techniques, for example,mechanical attachment, adhesive, thermal, or ultrasonic bonding.Preferably, the resealable label can be attached to the lid using anadhesive, more preferably a permanent adhesive. The resealable label canbe configured to be re-attached to the second layer when the flap andthe lid of the container are in the closed position.

The resealable label allows for repeated opening and closing of thesealed inner package to access the consumer goods individually. Theresealable label preferably provides sufficient adhesion for the accessopening to be opened and closed at least as many times as there areconsumer goods within the sealed inner package. The resealable labelpreferably enables a consumer to open and reseal the sealed innerpackage until the sealed inner package is empty of consumer goods.

The resealable label has an inner surface and an outer surface. Theouter surface of the resealable label can be configured to permanentlyattach the label and in some embodiments a portion of the sealed innerpackage to the inner surface of the front wall of the lid.

The inner surface of the resealable label can comprise at least anadhesive portion and a non-adhesive portion. The adhesive portion can besuch that movement of the lid between open and closed positionssimultaneously moves the access opening of the sealed inner package andthe sealed inner package itself between opened and closed positions. Inthe closed position, a flap and label cover the access opening of thesealed inner package and is resealably attached to the sealed innerpackage by the resealable adhesive. In the open position, the flap andlabel are at least partially detached from the sealed inner package andthe access opening of the sealed inner package is at least partiallyuncovered or opened. The adhesive portion of the label can utilize anadhesive for example, preferably a pressure sensitive adhesive. Thenon-adhesive portion of the inner surface of the label can be positionedat the lower end of the label, which will be towards the lower edge ofthe lid. The non-adhesive portion can allow for the resealable adhesiveportion to be more easily opened.

Disclosed containers also include at least one release element. Anysuitable release element may be employed in a container as describedherein. Preferably, a release element can comprise water or a humidityrelease agent, one or more sensory enhancing agents, one or morehumectants, one or more lipid compounds, one or more additionalcompounds, or any combination thereof. Preferably, if the releaseelement includes a core, the core preferably consists essentially of, orconsists of, a mixture of one or more of water or a humidity releaseagent, one or more sensory enhancing agents, or a combination thereof;one or more humectants; one or more lipid compounds; and optionally oneor more additional compounds.

Some release elements can include water, a humidity release agent, orboth. Such release elements can be useful to allow for ongoing controlof the humidity level within the sealed inner package. Preferably, thewater or humidity release agent can be contained within awater-insoluble core that upon application of pressure thereto releasesthe water or humidity release agent into the sealed inner package.

Some release elements can include a sensory-enhancing agent either withor in place of water or a humidity release agent. Any suitablesensory-enhancing agent may be included in a release element. Suitablesensory-enhancing agents include flavourants and sensation agents.Suitable flavourants include aromatic or fragrance molecule asconventionally used in the formulation of flavoring or fragrancecompositions.

Those sensory-enhancing agents having limited low or medium solubilityin water may benefit from high concentrations of lipid compounds in themixture of the core, if a core is utilized in the release element, asthey may be more soluble in the lipid component. Those sensory-enhancingagents having high solubility in water will likely be present in thehydrophilic portion of the core, if a core is utilized in the releaseelement, such as with hydrophilic humectants.

The concentration of sensory-enhancing agent in a release element can beadjusted or modified to provide a desired amount of thesensory-enhancing agent. Thus, the concentration of sensory-enhancingagent within each release element can be the same or can vary dependingon the desired sensory result.

Preferred release elements can include a core and a shell. Some suchrelease elements can include, along with water or a humidity releaseagent, sensory-enhancing agents or both, humectants, lipids, othercomponents, or a combination thereof.

Preferably, one or more of the humectants in the core are hydrophilic,that is, the humectant is a molecule that is at least partiallypolarized and capable of hydrogen bonding, enabling it to dissolve morereadily in water than in oil. As used herein, “hydrophilic” means havinga solubility in water of 25 grams or more per 100 milliliters at 25degrees Celsius. Accordingly, “hydrophobic” means having a solubility inwater of less than 25 grams per 100 milliliters at 25 degrees Celsius.In many cases, humectants have a solubility in water that is about 40grams or more per 100 milliliters at 25 degrees Celsius, such as about50 grams or more per 100 milliliters at 25 degrees Celsius.

A humectant can be present in the core or in the mixture in any suitableconcentration. For example, the cumulative concentration of the one ormore humectants in the mixture can be in a range from about 1 percent toabout 20 percent. Preferably, the cumulative concentration of the one ormore humectants in the mixture is in a range from about 2 percent toabout 15 percent. More preferably, the cumulative concentration of theone or more humectants in the mixture is in a range from about 7 percentto about 10 percent. Preferably, the mixture contains only onehumectant.

Preferably, the mixture containing the one or more lipid compounds andthe one or more humectants comprises an emulsion. One or more humectantscan optionally be dissolved in an appropriate solvent prior to mixturewith the one or more lipid compounds to favor formation of an emulsion.Similarly, the one or more lipid compounds can optionally be dissolvedin an appropriate solvent prior to mixture with the one or morehumectants. The mixture of one or more lipid compounds and one or morehumectants can include any suitable lipid compound.

Release elements can include a core and a shell. Any suitable shell thatis breakable via the application of a reasonable force can be utilized.For example, the shell of a release element can include one or morehydrocolloids, which can be, for example, gelatin or a vegetableingredient. For example, the shell can include gelatin; a modifiedstarch; a polysaccharide based material, such as pectin or alginate;gelatin; a paraffin wax; agar; algin; glycerol; arabic guar;carrageenan; a vegetable gum such as ghatti gum, pullulan gum, mannangum; or any other suitable material or combinations thereof. Preferably,the shell contains an alginate.

The shell may further include one or more fillers. As used herein a“filler” is any suitable material that can increase or decrease thepercentage of dry material in the shell, or change the viscoelasticproperties of the shell (such as a plasticizer). Increasing the drymaterial amount in a shell can result in solidifying the shell, and inmaking the shell physically more resistant to deformation. Preferably,the filler is selected from the group comprising starch derivatives suchas dextrin, maltodextrin, cyclodextrin (alpha, beta or gamma). Dextrinis a preferred filler. The amount of filler in the shell is generally98.5 percent or less, preferably from about 25 percent to about 95percent, more preferably from about 40 percent to about 80 percent, andeven more preferably from about 50 percent to about 60 percent by weightof the total dry weight of the shell.

In some preferred embodiments, the shell includes one or morehumectants. The one or more humectant can account for any suitableweight percentage of the shell. In particularly preferred embodiments,the shell includes an alginate and a humectant.

The shell of a release element may be of any suitable thickness. In someembodiments, the shell thickness of the capsule is from about 10 micronsto about 500 microns, preferably from about 20 microns to about 150microns, more preferably from about 30 microns to about 80 microns.

A release element in accordance with the teachings presented herein mayhave any suitable ratio of the weight of the shell to the weight of therelease element. For example, the ratio of the weight of the shell tothe total weight of the release element can be from about 5 percent toabout 15 percent, preferably from about 6 percent to about 10 percent,more preferably from about 8 percent by weight/total weight of therelease element.

The core may represent any suitable weight percent of the releaseelement. For example, the core of a release element represents by weightfrom about 85 percent to about 95 percent of the total weight of therelease element, preferably from about 90 percent to about 94 percent byweight, more preferably from about 92 percent by weight of the totalweight of the release element.

A release element may have any suitable total weight. The total weightof the release element can be from about 5 mg to about 60 mg, preferablyfrom about 10 mg to about 50 mg, more preferably from about 15 mg toabout 40 mg. For example, a release element with a diameter of 3.5 mmmay weigh 22 mg and a release element of diameter of 3.0 mm may weigh 17mg.

A release element in accordance with the teachings presented herein mayhave any suitable outer diametric dimensions. In some embodiments, theouter diameter of the release element is in the range of about 2 mm toabout 7 mm, preferably from about 3 mm to about 6 mm, more preferablyfrom about 4 mm to about 5 mm.

It can be appreciated that a multitude of processes exist formanufacturing release elements. Accordingly, the release element can beof varying size and shape, differing resistance to kinetic or thermalforces to break or rupture the release element, and can includealternative compositions and constituents.

In some embodiments, a release element can be a seamless capsuleobtained through a co-extrusion process. The co-extrusion process can bea synchronous extrusion of two liquids: an external and hydrophilicliquid phase, and an internal and lipophilic liquid phase. Preferably,the co-extrusion process includes three main stages: compound dropformation, shell solidification and capsule collection. The compounddrop is a sphere of the liquid fill phase inside the shell phase. Theliquid fill phase constitutes the core. The shell phase constitutes theshell. The release element of the invention may be produced by anysuitable co-extrusion process, such as described in EP1906775 orEP513603.

In some embodiments, the release element can be formed by any methodsknown in the art that comprise dripping of a core emulsion and a shellsolution into gelation bath, such as but not limited to, simpledripping, drip casting, electrostatic dripping, coaxial air flowtechnique, liquid-jet breakup technique, vibrating jet (nozzle) breakuptechnique, jet cutting technique, and rotating (or spinning) diskatomization.

Preferably, the release elements are crushable. As used herein, acrushable release element is a release element having a crush strengthfrom about 0.01 kp to about 5 kp, preferably from about 0.5 kp to about2.5 kp. The crush strength of the release element can be measured bycontinuously applying a load vertically onto one release element untilrupture. The crush strength of the release elements can be measured byusing a LLOYD-CHATILLON Digital Force Gauge, Model DFIS 50, having acapacity of 25 kg, a resolution of 0.02 kg, and an accuracy ofplus/minus 0.15 percent. The force gauge can be attached to a stand; therelease element can be positioned in the middle of a plate that is movedup with a manual thread screw device. Pressure can then be appliedmanually. The gauge records the maximum force applied at the very momentof the rupture of the release element (measured in, for example, kg orin lb). Rupture of the release element results in the release ofcontents of the core.

Additional methods for characterizing release element include crushforce which is the maximum compressive force measured in, for example,Newtons that a release element can withstand before breakage alsoreferred to as the maximum resistance to breakage; and distance atbreakage which is the change in dimension of the release element due tocompression, that is, deformation, at breakage. It can also be expressedfor example by the ratio between a dimension of the release element (forexample, the release element diameter) and the dimension of the releaseelement, measured in the direction of the compression force, when it iscompressed to the point of breakage. The compression is generallyapplied toward the floor by the compression plates of an automatic ormanual compression testing machine. Such machines are well known in theart and commercially available.

The release element should have characteristics that allow the water orhumidity release agent, sensory enhancing agent or both to be releasedinto the sealed inner package without damaging the container, theconsumer goods within the container, or both.

In preferred embodiments, the release element has a crush strength priorto introduction into the container of from about 0.6 kp to about 2 kp,preferably from about 0.8 kp to about 1.2 kp. Preferably, the releaseelement has a maximum resistance to breaking of about 17 N, preferablyabout 14 N. The above maximum resistance to breaking is typicallyobtained when a universal tensile/compression testing machine equippedwith 100 N tension load cell like, Instron or equivalent, is operatingat about 30 mm/min and at 22 degrees Celsius under 60 percent relativehumidity. An example of a manual test machine is the Alluris TypeFMI-220C2-Digital Force Gauge 0-200N-Supplier: Alluris GmbH & Co.

The one or more release elements may be located at various locationswithin the container. The release elements are always located so thatthey are within the sealed inner package even after the inner packagehas been resealed. In some embodiments, the one or more release elementscan be located so that the sealing and resealing of the inner package isnot affected by their presence. In some embodiments, the one or morerelease elements are located above the portion of the box where theresealable portion of the lid contacts the box. In some embodiments, theone or more release elements are located between the inner liner and anoptional pressure resistant element. In some embodiments, the one ormore release elements can be located within the portion of the sealedinner package that is within the lid.

In some embodiments, the one or more release elements can be locatedwithin the portion of the sealed inner package adjacent a side wall ofthe lid or the box, or both. In some embodiments, the one or morerelease elements can be located within the portion of the sealed innerpackage adjacent a back wall of the lid, the box, or both. In someembodiments, the one or more release elements can be located within theportion of the sealed inner package adjacent a front wall of the lid,the box, or both. In some embodiments, the one or more release elementscan be located within voids of smoking articles contained within theinner package.

Such embodiments, may be advantageous because the overall thickness ofthe package would not be affected, and the container would not have tobe modified to compensate for the thickness of the release elements. Insome embodiments, the one or more release elements are located at anycombination of locations. The one or more release elements can have thesame or different shapes. A desired shape of a release element maydepend in part on the location of the release element within thecontainer.

The container can also comprise a pressure resistant element. Thepressure resistant element may provide resistance against the forcenecessary to release materials from the release element. In someembodiments, a pressure resistant element can be an optional inner framedisposed within the sealed inner package. The inner may be disposed forexample adjacent the front wall, the back wall, the right side wall, theleft side wall, the top wall, the bottom wall of the sealed innerpackage. In some embodiments, the inner frame can be disposed adjacentthe same portion of the sealed inner package as the release element. Forexample, if the release element is adjacent a front wall of the sealedinner package, the inner frame can also be adjacent the front wall ofthe sealed inner package. Advantageously, an inner frame with a largesurface area provided adjacent the front wall of the sealed innerpackage increases the structural strength of the overall container. Anoptional inner frame may also provide resistance against force necessaryto release material from the release element. This may be particularlyadvantageous for subsequent use when the container is no longer full.

A container can also optionally include an inner stiffener as a pressureresistant element. An inner stiffener can be a piece of cardboard,paperboard, plastic, metal, or other material that can function toprotect the consumer goods contained in the sealed inner packageparticularly during the manufacturing of the container, even moreparticularly during sealing operations. Such an inner stiffener can bedisposed adjacent the front wall, the back wall, the right side wall,the left side wall, the top wall, the bottom wall, or any combinationthereof of the sealed inner package. In some embodiments, the innerstiffener can be disposed adjacent the same portion of the sealed innerpackage as the release element. For example, if the release element isadjacent a front wall of the sealed inner package, the inner stiffenercan also be adjacent the front wall of the sealed inner package.Advantageously, an inner stiffener with a large surface area providedadjacent the front wall of the sealed inner package increases thestructural strength of the overall container. An optional innerstiffener may also provide resistance against force necessary to releasematerial from the release element. This may be particularly advantageousfor subsequent use when the container is no longer full.

In some embodiments, a container can include visible indicia indicatinglocation, identity, or both of the one or more release elements. Forexample, indicia could be located on the outer surface of the sealedinner package to indicate position, identity (for example, type offlavourant, humidity release agent or water), or both. For example,indicia could be located on the outer surface of the box, the outersurface of the lid, or both to indicate position, identity (for example,type of flavourant, humidity release agent or water), or both.Optionally, the portion of the housing (lid, box, or both) overlying therelease elements may be debossed or thinned to compensate for thepressure of the release element or elements.

A carton that includes a lid and at least one sidewall can containmultiple containers as described herein. A carton comprises houses orholds at least one container. A carton can contain only disclosedcontainers or can contain disclosed containers as well as other items.In some preferred embodiments, a carton comprises houses or holds fromfive to ten disclosed containers.

Also disclosed herein are methods of forming disclosed containers.Methods can include steps of forming a sealable inner package or aprecursor to a sealable inner package; disposing at least one releaseelement in or on the sealable inner package;

disposing at least one consumer good in the sealable inner package; andsealing the sealable inner package so that the at least one consumergood and the at least one release element are contained therein to formthe container. The step of forming a sealable inner package or aprecursor to a sealable inner package can be accomplished by providingmaterial (for example plastic, paper, foil, or other materials asdescribed above) that once manipulated (for example folded, crimped,cut, adhered to itself or some other material, or other actions) forms asealable or sealed inner package. Characteristics of sealed innerpackages, release elements, consumer goods and other features ofcontainers described above can all be utilized in disclosed methods.

The term “inner surface” is used throughout the specification to referto the surface of a component of the assembled container that is facingtowards the interior of the container, for example towards the consumergoods, when the container is in the closed position. For example, theouter film comprises an inner surface that is facing the housing of thecontainer.

The term “outer surface” is used throughout the specification to referto the surface of a component of the container that is facing towardsthe exterior of the container. For example, the outer film comprises anouter surface that is facing away from the housing of the container. Itshould be noted that the inside or outside surface is not necessarilyequivalent to a certain side of a blank used in assembly of thecontainer. Depending on how the blank is folded around the consumergoods, areas that are on the same side of the container can either facetowards the inside or the towards the outside of the container.

The terms “front,” “back,” “upper,” “lower,” “top,” “bottom,” and “side”refer to the relative positions of portions of containers according tothe invention and components thereof when the container is in an uprightposition with the lid of the housing in the closed position and thehinge line at the rear of the container. When describing containersaccording to the present invention, these terms are used irrespective ofthe orientation of the container being described. The rear or back wallof the container includes the hinge line.

All scientific and technical terms used herein have meanings commonlyused in the art unless otherwise specified. The definitions providedherein are to facilitate understanding of certain terms used frequentlyherein.

Referring now to the drawings, in which some aspects of the presentinvention are illustrated.

FIG. 1 is a schematic perspective view of a container in an openposition, where the container comprises at least one release element.

FIG. 2 is a schematic perspective view of the side of the container ofFIG. 1 in an open position.

FIG. 3 is a schematic perspective view of the front of the container ofFIG. 1 in a closed position.

FIG. 4 is a schematic perspective view of a container in a closedposition where the container comprises indicia to indicate location andidentity of the release elements.

Referring to FIGS. 1 and 2, a schematic perspective view of anembodiment of a container 10 for consumer goods is depicted. Thecontainer includes a housing 12 that includes a box 14 and a lid 20hingedly attached to the box via a hinge line (not shown). The box has afront wall 16 and a rear wall 18. The front wall of the box has an upperedge 21. The box also has an inner surface 17 and an outer surface 19.The hinge line extends across the back wall 18 of the box 14 of thecontainer 10, and acts to allow the lid 20 to be moved from a closedposition (FIG. 3) to an open position as shown in FIGS. 1 and 2. The lid20 has a front wall 24 that has an inner surface 22 and an outer surface26. The lid 20 also has a lower edge 25.

An inner package 30 is disposed within the housing 12. The inner package30 at least partially defines an interior volume or sealed volume forhousing consumer goods. The inner package 30 can be made from a barriermaterial or materials to hermetically seal the consumer goods before thecontainer is opened for the first time. The barrier material may be ametal foil or a plastic and metal laminate. The inner package 30includes a front wall 32, a back wall 34, a bottom wall 35, a top wall36, a right side wall 37 and a left side wall (not shown). The innerpackage 30 includes an outer surface 33.

The inner package 30 includes an access opening 54 through which theconsumer goods (not shown) can be removed. The access opening 54 iscovered by the flap 44 when the flap is in the closed position (FIG. 3).Further, the access opening 54 is at least partially uncovered when theflap 44 is in the open position. The flap can include or be coupled witha label. The label includes a sealing area and a non-sealing area. Theflap and the label are not distinguishable in the figures and element 44can be considered as referring to both of them. The flap 44 can beattached to the top wall 36 along a hinge line 49 (FIG. 2). The flap 44is also attached to an inner surface 22 (FIG. 2) of the front wall 24 ofthe lid 20 such that upon opening the lid the flap and a portion 55 ofthe second layer 50 of the sealed inner package 30 attached to the flapare separated from the sealed inner package 30 along first and secondlines of weakness (not shown herein) to reveal the access opening 54.The flap 44 is adapted to overlap the access opening 54 into a sealingregion 75 such that the flap attaches to the second layer 50 within thesealing region 75 when the flap is in the closed position. FIG. 1 alsoshows an optional pressure resistant element 70. The pressure resistantelement 70 is located within the sealed inner package 30.

Referring to FIG. 2, a schematic cross-section view of the container 10of FIG. 1 is depicted with the lid 20 and the flap 44 in the openposition. The inner package 30 is shown disposed within the box 14 ofhousing 12. The flap 44 is attached to the lid 20. In the open position,the flap 44 forms an S-shape. The geometry of the container 10 is suchthat the flap 44 is automatically resealed to the sealed inner package30 when the flap (and the lid 20) is returned to the closed position.

Referring to FIG. 3, a schematic perspective view of the container 10 ofFIG. 1 is depicted. The lid 20 of the container 10 and the flap 44 ofthe inner package 30 are in the closed position. The flap 44 is attachedto the second layer 50 when the flap is in the closed position.

All of the figures also show release elements 72. The release elements72 are positioned so that they are within the sealed interior volumewhen the sealed inner package 30 is closed. In the particularembodiments depicted in FIGS. 1 to 3, the release elements 72 arepositioned above the upper edge 21 of the box 14 and above the loweredge 25 of the lid 20 when the lid is in the closed position (FIG. 3).The release elements 72 are also positioned above the sealing region.

FIGS. 1, 2 and 3 show three release elements 72 but any number ofrelease elements can be utilized in disclosed containers.

FIG. 4 shows release elements 72 positioned adjacent the inner surfaceof the front wall 16 of the box 14. The outer surface 19 of the frontwall 16 of the box 14 includes location indicia 80, 81 and 82 as well asidentity indicia 83, 84 and 85.

1. A container for consumer goods, comprising: a housing comprising abox and a lid hingedly attached to the box, wherein the box comprises abox front wall and an interior box volume and wherein the lid comprisesa lid front wall; a sealed inner package disposed at least partiallywithin the interior box volume and defining an interior sealed volumefor housing consumer goods; a resealable flap configured to open andclose the sealed inner package when the lid of the housing is opened andclosed, wherein the resealable flap is positioned to cover an accessopening in the sealed inner package, where the access opening extends atleast partially across the top wall of the inner package; at least onerelease element positioned within the interior sealed volume of thesealed inner package even after the sealed inner package has been openedand closed; and a pressure resistant element positioned inside thesealed inner package, wherein the pressure resistant element and the atleast one release element are positioned such that a force applied fromthe outside of the container can cause the at least one release elementto release at least some material therefrom.
 2. The container accordingto claim 1, wherein the front wall of the box comprises a box front wallupper edge and the front wall of the lid comprises a lid front walllower edge and the at least one release element is positioned above thebox front wall upper edge and above the lid front wall lower edge. 3.The container according to claim 1, wherein the sealed inner packagefurther comprises a front wall, a back wall, a right side wall, a leftside wall, a top wall and a bottom wall and the at least one releaseelement is positioned adjacent at least one of the front wall, the backwall, the right side wall, the left side wall, the top wall, the bottomwall, or a combination thereof.
 4. The container according to claim 3,wherein the pressure resistant element and the at least one releaseelement are positioned adjacent the same wall or walls of the sealedinner package and the at least one release element is located betweenthe sealed inner package and the pressure resistant element.
 5. Thecontainer according to any of claims 1, wherein the pressure resistantelement is an inner frame, an inner stiffener or both.
 6. The containeraccording to claims 1, wherein the access opening also extends at leastpartially across the front wall, the back wall, or both of the sealedinner package.
 7. The container according to any of claims 1, whereinthe resealable flap comprises a label adhered to the sealed innerpackage.
 8. The container according to any of claims 1, wherein theresealable flap is integrally formed from the sealed inner package. 9.The container according to claim 1, wherein the release elementcomprises water or a humidity release agent, a sensory-enhancing agent,or a combination thereof.
 10. The container according to claim 1,wherein the release element has a maximum resistance to breaking of 17N.
 11. The container according to claim 1, wherein the containercomprises at least two release elements.
 12. The container according toclaim 1, wherein the sealed inner package comprises an inner surface andan outer surface and the outer surface comprise indicia that locates theat least one release element, identifies the at least one releaseelement, or both.
 13. A method of forming a container, the methodcomprising: forming a sealable inner package, the sealed inner packagecomprising an access opening that extends at least partially across atop wall of the sealed inner package; disposing at least one releaseelement in or on the sealable inner package; disposing at least oneconsumer good in the sealable inner package; disposing a pressureresistant element inside the sealed inner package, wherein the pressureresistant element and the at least one release element are positionedsuch that a force applied from the outside of the container can causethe at least one release element to release at least some materialtherefrom; positioning a resealable flap to cover the access opening ofthe sealed inner package, the resealable flap configured to open andclose the sealed inner package when the lid of the housing is opened andclosed; sealing the sealable inner package so that the at least oneconsumer good and the at least one release element are containedtherein; forming a housing, the housing comprising a box and a lidhingedly attached to the box, wherein the box has an interior boxvolume, wherein the sealed inner package is disposed at least partiallywithin the interior box volume to form the container.
 14. The method ofclaim 13, wherein the at least one release element is disposed thesealable inner package.
 15. The container according to claim 9, whereinthe release element has a maximum resistance to breaking of 17 N. 16.The container according to claim 9, wherein the container comprises atleast two release elements.
 17. The container according to claim 11,wherein the sealed inner package comprises an inner surface and an outersurface and the outer surface comprise indicia that locates the at leasttwo release elements, identifies the at least two release elements, orboth.
 18. The container according to claim 11, wherein the sealed innerpackage comprises an inner surface and an outer surface and the outersurface comprise indicia that both locates the at least two releaseelements and identifies the at least two release elements.